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Mitsubishi Galant (2004+). Manual - part 602

ROCKER ARMS AND CAMSHAFT

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ENGINE OVERHAUL <3.8L ENGINE>

11D-25

Required Special Tools:

• MB991559: Camshaft Oil Seal Installer Adapter

• MD998442: Air Bleed Wire

• MD998443: Lash Adjuster Holder

• MD998713: Camshaft Oil Seal Installer

REMOVAL SERVICE POINT

<<A>> ROCKER ARMS AND SHAFT REMOVAL

CAUTION

If the lash adjuster is re-used, clean the lash adjuster.
(Refer to lash adjuster inspection

P.11D-27

Set special tool MD998443 to prevent the lash adjuster from
coming free and falling to the floor.

INSTALLATION SERVICE POINTS

>>A<< CAMSHAFT INSTALLATION

CAUTION

Use care to prevent confusion of the right and left bank
camshafts.
1. Apply engine oil to the camshaft journals and cams and then

install the camshafts.
NOTE: The camshaft with a longer overall length is for the
left bank.

2. Check to see that the dowel pin of the camshaft is located at

the position shown.

AKX00613AB

MD998443

AK204034AB

TIMING BELT SIDE

CAMSHAFT, LEFT

CAMSHAFT, RIGHT

AK204035AB

APPROXI-
MATELY
60˚

RIGHT BANK

LEFT BANK

APPROXI-
MATELY
71˚

ROCKER ARMS AND CAMSHAFT

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ENGINE OVERHAUL <3.8L ENGINE>

11D-26

>>B<< LASH ADJUSTER INSTALLATION

CAUTION

If the lash adjuster is re-used, clean the lash adjuster.
(Refer to lash adjuster inspection

P.11D-27

Fit the lash adjuster onto the rocker arm without allowing diesel
fuel to spill out. Fit special tool MD998443 to prevent the lash
adjuster coming from free and falling to the floor.

>>C<< ROCKER ARMS AND SHAFT INSTALLATION
1. Position the end with the larger chamfer at the right on the

front bank, and at the left on the rear bank.
NOTE: The side with the four bolt holes is on the intake side.

2. Position the side with the oil holes on the lower side

(cylinder head side).

>>D<< CAMSHAFT OIL SEAL INSTALLATION
Use special tools MD998713 and MB991559 to install the cam-
shaft oil seal.

AKX00715

MD998443

LASH
ADJUSTER

AK202325

TIMING BELT SIDE

CHAMFERED

OIL HOLE

AKX00615

MD998713

AKX00639

MB991559

MD998713

ROCKER ARMS AND CAMSHAFT

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ENGINE OVERHAUL <3.8L ENGINE>

11D-27

INSPECTION

M1113005500463

ROCKER ARM SHAFT
Check the rocker arm mounting areas of the rocker arm shafts
for wear or damage. Replace as necessary.

ROCKER ARM
1. Check the roller surface and replace the rocker arm if

recesses, damage or heat seizure is observed.

2. Check roller rotation and replace the rocker arm if uneven

rotation or roller backlash of the roller is observed.

3. Check the inside diameter and replace the rocker arm if

damage or seizure is observed.

CAMSHAFT
1. Check the camshaft bearing journals for damage and

binding. If the journals are binding, check the cylinder head
for damage. Also check the cylinder head for clogged oil
holes.

2. Check the tooth surface of the distributor drive gear teeth of

the camshaft and replace if abnormal wear is evident.

3. Check the cam surface for abnormal wear and damage and

replace if necessary. Also measure the cam height and
replace if out of minimum limit.

Standard value:

Intake 37.39 mm (1.472 inches)
Exhaust 37.71 mm (1.485 inches)

Minimum limit:

Intake 36.89 mm (1.452 inches)
Exhaust 37.21 mm (1.465 inches)

LASH ADJUSTERS

CAUTION

• The lash adjusters are precision-engineered mecha-

nisms. Do not allow them to become contaminated by
dirt or other foreign substances.

• Do not attempt to disassemble the lash adjusters.
• Use only fresh diesel fuel to clean the lash adjusters.

1. Prepare three containers and approximately 5 dm

(30.5

quart) of diesel fuel. Into each container, pour enough diesel
fuel to completely cover a lash adjuster when it is standing
upright. Then, perform the following steps with each lash
adjuster.

AKX00723

ROLLER TIP

AKX00685

AKX00625

OUTSIDE
CLEANING

INSIDE
CLEANING

FILLING
DIESEL FUEL

ROCKER ARMS AND CAMSHAFT

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ENGINE OVERHAUL <3.8L ENGINE>

11D-28

2. Place the lash adjuster in container A and clean its outside

surface.
NOTE: Use a nylon brush if deposits are hard to remove.

CAUTION

The steel ball spring is extremely weak, so the lash
adjuster's functionality may be lost if the air bleed wire is
pushed in hard.
3. While gently pushing down the internal steel ball using wire

[0.5 mm (0.020 inch) in diameter] or special tool MD998442,
move the plunger through five to ten strokes until it slides
smoothly. In addition to eliminating stiffness in the plunger,
this operation will remove dirty oil.
NOTE: If the plunger remains stiff or the mechanism
appears otherwise abnormal, replace the lash adjuster.

4. Remove the lash adjuster from the container. Then, push

down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.

CAUTION

The steel ball spring is extremely weak, so the lash
adjuster's functionality may be lost if the air bleed wire is
pushed in hard.
5. Place the lash adjuster in container B. Then, gently push

down the internal steel ball using a wire [0.5 mm (0.020
inch) in diameter] or special tool MD998442 and move the
plunger through five to ten strokes until it slides smoothly.
This operation will clean the lash adjuster's pressure
chamber.

6. Remove the lash adjuster from the container. Then, push

down the steel ball gently and push the plunger to eliminate
diesel fuel from the pressure chamber.

AKX00626

DIESEL
FUEL

AK202680

DIESEL FUEL

MD998442

AK202681

DIESEL FUEL

MD998442

AK202680

DIESEL FUEL

MD998442

AK202681

DIESEL FUEL

MD998442

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